leroy somer

v. 1.01

SYNCHRONOUS ALTERNATOR

FCC MIRPUR MATHELO

Serial number 603411

Type LSA58 BMCL140Power 17000 kVAVoltage 6300 VPower factor 0,8Frequency 50 HzSpeed 1500 rpm

ALTERNATORSService & Operating Manual

LEROY SOMER Service & Operating Manual SECTION 0ALTERNATORS

CONTENTS

VOLUME CONTENTS

SECTION 0 VOLUME CONTENTSWARNING

SECTION 1 Generator Data SheetSpare Parts List

SECTION 2 TEST REPORT(AVR Settings)

SECTION 3 Service & Operating Manual

SECTION 4 Automatic Voltage Regulator

SECTION 5 DrawingsDedicated manuals for specific equipement


CONTENTS

FOREWORD

WARNING

THIS INSTALLATION AND MAINTENANCE MANUAL CONCERNS A COMPLETE RANGE OF MACHINES.

SECTION 1 OF THIS MANUAL "DATA SHEET "ENABLES YOU TO IDENTIFY THE CONSTITUTIVE

ELEMENTS OF YOUR PARTICULAR MACHINE


Generator Data Sheet

SECTION 1

Generator Data SheetSpare Parts List

TABLE OF CONTENTS

1. MACHINE TECHNICAL DATA

1.1 General characteristics

1.2 Excitation - Regulation

1.3 Stator protections

1.4 Not applicable

1.5 Not applicable

1.6 Sleeve bearing technical data

1.7 Drive end bearing Protection

1.8 Non drive end bearing Protection

1.9 Not applicable

1.10 Not applicable

2. SPARE PARTS

2.1 To order spare parts

2.2 Recommanded spare parts

LEROY SOMER SECTION 1Service and Operating Manual

Generator unit

1. MACHINE TECHNICAL DATA

1.1 General characteristicsProject FCC MIRPUR MATHELOType A58 BMCL140 Turb gazSerial Nr 603411Synchronous TriphasedConnections StarRated output 17000 KVAVoltage 6300 VFrequency 50 HzPower Factor 0.8Polarity 4Speed 1500 RPMMachine protection IP21Insulation HTemperatue rise FGenerator air gap 16 mmExciter air gap 2 mmAmbient temperature 40 CCooling IC 0 A1Weight of rotor 10239 KgTotal weight 30502 Kg

1.2 Excitation - RegulationAVR type AREP

1.3 Stator protections Space heater (W) 1000under(V) 230Stator winding sensor 6 x PT100

LEROY SOMER SECTION 1Service and Operating Manual

Generator unit

1.6 Sleeve bearing technical dataDrive Non drive

End side End sideType EFZLK 22-225 EFZLQ 22-225Seal type Renk n 10 Renk n 10Seal type Renk n 10 Renk n 10Cooling / Lubrication (*1) Oil circulation (gravity return) Oil circulation (gravity return)

Axial clearance, bearing type Locating Non locatingAxial clearance (mm) 0.5Diametral clearance (mm) 0.378 0.378Oil type VG46 VG46losses (kW) 6.4 4.1Oil sump capacity (l) 21 21Bearing shell temperature (C) 51.4 57Oil film thickness (mm) 0.067 0.069Refrigerant flow rate (l/min) 17 7Accuracy of flow rate regulation (weak) ; +0% -40% (weak) ; +0% -40%Inlet temperature (C) 40 40Attitude angle (beta ; ) 42.4 43Rotation Counter Clock WiseShaft displacement "X" 0.08 (Refer to chapter 4.3)Shaft displacement "Y" 0.09 (Refer to chapter 4.3)

1.7 Drive end bearing ProtectionOil sump sensor 13190801400

1.8 Non drive end bearing ProtectionOil sump sensor 13190801400

LEROY SOMER Service and Operating Manual SECTION 1

Generator unit

2. SPARE PARTS

2.1 To order spare parts1-Identify the machine Serial Numberon the name plate (eg : 71 155 513)2- Identify the part number using the attacheddrawings and give a description

2.2 Recommanded spare partsShell 1 EFZLK 22-225Rotating diodes 6 SKN240/12Bearing temperature sensor 1 13190801400

LEROY SOMER Service and Operating Manual SECTION 1

Generator unit

Date : LS Reference : 603411 330-mars-10

Customer : Turbomach 1Project : FCC MIRPUR MATHELO 1

Moteurs Leroy Somer Tel. : +33 (0)2 38 60 48 46 Charg d'Affaire : NC 1ACEO Fax: +33 (0)2 38 60 42 851 RUE DE LA BURELLE [email protected] 603411 145800 ST JEAN DE BRAYE NCSubject: V3.21 - 07/2010Site : PAKISTAN Prime mover : Gas turbine 1Application : Base Rating Manufacturer : Solar 1

Type : Titan 130 1

Main data: QuantityGenerator type: LSA 58 BMCL140 / 4p 1 1Power: 17 000 kVA 13 600 kWe 13 927 kWm 1Voltage: 6300V Star connection 5% Nominal curent: 1 558 A 1Power factor: 0,8 1Frequency: 50 Hz Speed: 1500 rpm 1Winding pitch : p5/6 Ambient: 40 C 1Insulation / Temperature rise : H / F Altitude: 1000 m 1

Electrical data:Efficiency: 110% 100% 75% 50% 25%

Power factor 0,8: 97,7 % 97,6 % 97,4 % 96,6 % 94,0 % 1Power factor 1,0: 98,1 % 98,0 % 97,7 % 96,8 % 94,2 % 1

Reactances Unsaturated, (rated KVA): (%) time constants:SCR: Xd Xq X'd X'q X"d X"q X2 Xo T'do T'd T''d Ta0,54 205 123 27,7 123 19,8 24,7 22,3 13,9 7,202 0,974 0,045 0,251 1

Saturated, (rated KVA): (%) SecondsRa (%) Xds Xqs X'ds X'qs X"ds X"qs X2s Xo T''do T'q T"q T''qo

0,3 185 111 23,5 111 16,8 21,0 18,9 13,9 0,063 NA 0,041 0,202 1

Mounting : IM1001 1Mounting : Two bearing Axis : horizontal 1Rotation : Counter clockwise (seen when facing the D-end) 1Bearing type: Sleeve - oil circulation with external lube oil set 1Bearing insulation : 1 bearing insulated 1Shaft end : Standard bare keywayed 1Balancing : Full key / balancing class : G1 1Flange : None / without 1Shaft height : 1000 mm / Width : 1870 mm 1Axial clearance : Standard 1

Comments: 1-

Cooling : IC01 1Protection : IP21 1Cooler : Coolant : Air / Temperature : 40 C 1Air quality : Clean 1Ventilation (internal) : Self vent. 1Filter : without filter 1Ducting (I / O) : No 1

Comments: 1

603411 rev. 3 Page 1 Comm - Ordo - Tech - Elec - Essa - Mont - Expe - Agen



-Connection & regulation: Radio int. suppression: Class N 1Parallel operation : With mains (3F) 1Type of excitation: AREP + PMI 1Sustained three phase short circuit : greater than 3 x FLC for 10 seconds 1AVR type: R610 (For panel mounting) 1Voltage sensing : Terminal box mounted voltage sensing VTs / 1With Voltage potentiometer : Digital / LS Supply 1With PF potentiometer : Digital / LS Supply 1

Comments: 1-

Protection and measurement accessories 1With guide bearing sensor : = 1 X PT100 per bearing 1With Winding sensors : = 6 x PT100 1With Anti-condensation heater : Voltage : 230 V / 1Ph / Power : 1000 W 1With Rotor earthing brush 1With Rotor Insulation measuring slip ring 1

Comments: 1

LS Supply 1Set of measuring or protection CTs: I Primary (A) I Secondary (A) Power (VA) Class

S1 2000 1 20 0.5FS5 2S2 2000 1 20 5P10 2

Neutral side S3 2000 1 20 5P10 3S1 2S2 2

Line side S3 2

Comments: 1LS Supply 1Set of Voltage measuring VTs: U Primary (V) U Secondary (V) Power (VA) Class

S1 3810,5 63,51 30 1 2S2 3810,5 36,67 30 3P 2

Line side S3 2

Comments: 1-

Terminal box : Power connection : 4 connectors (brought out neutral) 1Line side outlet : Refer to comments 1Extension on phase side : straight / length = 920 mm 1Gland plate : Non magnetic 1

Comments: Sortie vers l'arrire. BB avec manchette spciale identique TB 603 144. 1-

Various items : Overspeed : 1800 rpm / Duration (min.) : 2 1Requested noise level : 1Vibration sensors : Accelerometer (sismic) / Supplied by others 1location : Z 1 Drive end & 1 Non drive end 1Vibration level : 1

Comments: 1Paint : C3M-P - Polyurethane - RAL 7032 1Documentation : PDF manual Language : anglais 1

Comments: 1




-Controls : Rules : CEI 1QUAL/INES/006 001 Measurement of winding resistance 1QUAL/INES/006 021 Insulation check on sensors (when fitted) 1QUAL/INES/006 002 Voltage balance and phase order check 1QUAL/INES/006 003 No load characteristics, no load losses 1QUAL/INES/006 004 Three phase short circuit characteristic 1QUAL/INES/006 005 On load test (subject to test bench capacity) 1QUAL/INES/006 007 Overspeed test 1QUAL/INES/006 008 Calculation of efficiency by summation of losses 1QUAL/INES/006 009 High potential test 1QUAL/INES/006 010 Insulation resistance measurement 1QUAL/INES/006 019 Measurement of specified vibration level 1

1-

Sleeve Bearing data:Bearing cooling : oil circulation with external lube oil set 1external lub oil set :supplied by the client 1oil type (viscosity) : mineral oil (Std) / / 1

Comments: 1With Jacking device : bearing equipment only / Connection Left side (from DE) 1oil inlet connection : Left side (from DE) 1oil outlet connection : Right side (from DE) 1guide bearing sensor : 1 X PT100 per bearing 1

Comments: 1-

Performances : Voltage accuracy : 0,5%Maximum inrush current for a voltage dip of 15% : 12034 kVAwhen starting an AC motor having a starting power factor between 0 and 0.4



TEST REPORT

SECTION 2

TEST REPORT(AVR Settings)

Ateliers de Constructions Electriques d'Orlans Configuration of AVR andSettings of Potentiometers

ACEO

Customer Turbomach Order Test date 30/06/2010

Type of AVR R610 Type of Generator A58 Order 603411

Rack C51950287A Driver C51950070G Digital settings C51950111FSerial N 10231948 Serial N 10133762 Serial N 10121526

P1 10 P1 10Power Block C51950306A P2 5 P2 4

Serial N 10231684 P3 5 P3 6P4 1 Jump U +/-

Generator I/O C51950233B P5 8(1volt) Jump Cos +/-Serial N 10191936 P6 2

Jump of select U 105V P7 7 Aux I/OP1 4 P8 10 Serial N

P1Rack supply C51950040G LEM C51950076F P2

Serial N 10183792 Serial N 10213321 P3Captor Hall 3 P4

Dtection Sensing C51950050G P5Serial N 10093682 Cos /kVAR C51950080F P6

P1 4 Serial N 10112678 P7P2 6.8 P1 5 Jump way 1P3 6.5 P2 5 Jump way 2P4 0 P3 6P5 5.8 P4 2.8

CV1 U/F P5 3P6 0

PID C51950060I P7 3Serial N 10192792 Select of droop -

P1 6P2 5P3 5P4 5P5 5P6 5P7 2.8P8 10

ST1 vers C4 Repere of ST2 inactif potentiometer

Tested by : BENA M

ELEC/FCTL/000 008

5

1 9


Service & Operating Manual

SECTION 3


2327 en 07.2009 / m

ALTERNATOR


LEROY SOMER SERVICE AND OPERATING MANUAL 2327 en 07.2009 / m

ALTERNATORS

3

TABLE OF CONTENTS

1. GENERAL INFORMATION

1.1 INTRODUCTION 1.1.0 General points 1.1.1 Safety notes 1.1.2 Conditions of use

a) Generalities b) Vibratory analysis

1.2 GENERAL DESCRIPTION 1.2.1 Generator 1.2.2 Excitation system

2. DESCRIPTION OF SUB-ASSEMBLIES

2.1 STATOR 2.1.1 Electric machine armature

a) Mechanical description 2.1.2 Excitation field winding 2.1.3 Stator protection

a) Heating resistor b) Stator winding temperature sensor c) Stator air sensor d) Stator vibration sensor

2.2 ROTOR 2.2.1 Revolving field-coil 2.2.2 Excitation armature 2.2.3 Fan (machines: IC 0 A1) 2.2.4 Rotating diode bridge

a) General points b) Tightening torque for the rotating diode

fastening screws c) Rotating rectifier test

2.2.5 Balancing 2.2.6 Rotor vibration sensor

2.3 ANTI FRICTION-BEARINGS (rolling bearing)

2.3.0 Description of antifriction bearings 2.3.1 Start-up of antifriction bearings 2.3.2 Storage of machine with anti friction

bearings

2.3.3 Maintenance of antifriction bearings a) General points b) Lubricant c) Cleaning bearings

2.3.4 Servicing the antifriction bearings a) General points b) Removing the bearings c) Bearing reassembly

2.3.5 Antifriction bearing protection devices 2.3.9 Antifriction bearing installation drawing

2.4 SLEEVE BEARINGS (Plain) 2.4.0 Description of horizontal Sleeve bearings

a) Physical description b) Operating description of Self-lubricating

bearing c) Operating description of Oil circulation bearing

2.4.1 Electrical insulation of Sleeve bearings a) Illustration diagram of the insulating film b) Insulation check

2.4.2 Storage of Sleeve bearings machine a) General points b) Short term storage c) Long term storage

2.4.3 Oil circulation installation 2.4.4 Start-up of Sleeve bearings

a) General check before start up b) Self-lubricating bearings start up data c) Water cooled bearing (type EFW..) start up

data d) Oil circulation bearing with non-accurate oil

flow (+0% ; -40%) e) Oil circulation bearing with accurate oil flow

(+5% ; -10%) f) Inspection of Sleeve bearings at the end of

start-up 2.4.5 Maintenance of Sleeve bearings

a) Verification of oil-level b) Temperature verification c) Oil draining d) Pressure measurement of a Sleeve bearing

housing e) Oil for sleeve bearing f) Oil sump capacity g) Sealing Compound


ALTERNATORS

4

2.4.6 Dismantling a) Tools and equipment b) Lifting equipment c) Dismantling of the shaft seal type 10 (outboard

side) d) Dismantling of the shaft seal type 20 (outboard

side) e) Dismantling of the top half of the housing f) Removal of the top half of the shell g) Dismantling of the loose oil ring h) Dismantling the machine side shaft seal i) Removal of the bottom half of the shell j) Dismantling of the machine seal

2.4.7 Cleaning and checking a) Cleaning b) Wear checking c) Insulation checking (only for insulated bearing)

2.4.8 Assembly of the Bearing a) Fitting in the bottom half of the shell b) Assembly of the shaft seal machine-side c) Installation of the loose oil ring d) Fitting in the top half of the shell e) Closing of the bearing f) Assembly of the type 10 Outboard Side Seals g) Assembly of the type 20 Outboard Side Seals h) Assembly of the RD-thrust pads ; bearing type

E...A 2.4.9 Oil-leakage trouble-shooting

a) Self-lubricating bearing b) Oil circulation bearing

2.4.10 Sleeve bearing protection devices a) Sight-level glass b) Oil thermometer c) Thermostat or sensor d) Pre lub pump

2.6 OIL CIRCULATION LUBRICATING UNIT 2.6.0 General points 2.6.1 Oil circulation by gravity return

a) General points b) Supply line c) gravity oil return

2.6.2 Oil cooling unit Air/Oil exchanger 2.6.3 Oil cooling unit Water/Oil exchanger

2.7 COOLER 2.7.0 Description of the cooler

a) General points b) Description of AIR-AIR coolers c) Description of AIR-WATER DOUBLE TUBE

EXCHANGER d) Description of AIR / WATER SINGLE TUBE

EXCHANGER 2.7.1 Cooler installation 2.7.2 Start-up of the cooler

a) General points 2.7.3 Maintenance of the water-cooler

a) General points b) Cleaning c) Leak detection for a double-tube exchanger

2.7.4 Servicing the water-cooler a) Cooler removal b) Cooler re-assembly

2.7.5 Cooler protection devices a) Leak detection (float system) b) Water temperature sensor c) Water filtering

2.8 AIR FILTERS 2.8.1 Cleaning

a) Air filter cleaning period b) Air filter cleaning procedure

2.18 TERMINAL BOX 2.18.0 Description 2.18.1 Electric panel

a) Compounding panel ( if compound regulator) b) Booster plate ( if shunt regulator)

2.18.2 Automatic voltage regulator 2.18.3 Electrical contact tightening

2.19 PROTECTION DEVICES 2.19.1 Stator protection devices 2.19.2 Bearing protection devices 2.19.3 Cooler protection devices

2.20 NAMEPLATES 2.20.1 Main nameplate 2.20.2 Lubrication nameplate 2.20.3 Rotation direction nameplate


ALTERNATORS

5

3. VOLTAGE REGULATOR AND EXTERNAL AUXILIARIES

4. INSTALLATION

4.1 TRANSPORT AND STORAGE 4.1.1 Transport 4.1.2 Storage warehouse 4.1.3 Maritime packing 4.1.4 Unpacking and installation 4.1.5 Storage measures of a site machine

4.2 INSTALLATION OF THE ELECTRIC MACHINE

4.2.1 Fitting the coupling (double-bearing machine only)

4.2.2 Fitting the stator

4.3 ELECTRIC MACHINE ALIGNMENT 4.3.1 Various alignment characteristics

a) General points b) Axis height Thermal elevation c) Sleeve bearing shaft elevation d) Antifriction bearing shaft elevation

4.3.2 Two bearings machine alignment a) machines without axial end play (standard) b) machines with axial end play

4.3.3 Single bearing machine alignment a) General points b) Single bearing machine except A56 equipped

with anti friction bearing c) Single bearing machine A56 Anti friction-

bearing, only 4.3.4 Alignment procedure

a) Checking "Double concentricity" alignment method

4.4 ELECTRICAL CONNECTIONS 4.4.0 General points 4.4.1 Phase-sequence

a) standard machine.IEC 34-8 b) if wanted, NEMA.

4.4.2 Insulating distances 4.4.3 Added products in the terminal box

5. START-UP

5.0 START-UP SEQUENCE 5.0.1 Static checks 5.0.2 Rotating checks

a) Rotating checks not excited b) Rotating checks at no load excited c) Generator and site safeties d) Rotating checks at full load

5.0.3 Generator Start Up check list

5.1 ELECTRICAL START-UP INSPECTION 5.1.0 General points 5.1.1 Windings Insulation 5.1.2 Electrical connections 5.1.3 Parallel operation

a) Definition of parallel operation b) Possibility of parallel operation c) Parallel coupling

5.2 MECHANICAL START-UP INSPECTION 5.2.0 General points

a) Alignment; fixing; prime mover b) Cooling c) Lubrication

5.2.1 Vibrations

6. PREVENTIVE MAINTENANCE

6.1 MAINTENANCE SCHEDULE

6.2 MECHANICAL MAINTENANCE 6.2.1 Air gap check

a) Double bearing machine b) Single bearing machine

6.2.2 Bolts tightening 6.2.3 Cleanliness

6.3 ELECTRICAL MAINTENANCE 6.3.1 Measuring instruments

a) Instruments used b) Identification of ohmmeter polarity

6.3.2 Insulation check of the winding a) General b) Armature insulation measure c) Field insulation measurement d) Exciter insulation measurement e) Polarisation index


ALTERNATORS

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7. SERVICING

7.1 GENERAL SERVICING

7.2 TROUBLE SHOOTING 7.2.0 General points 7.2.1 Regulator trouble-shooting procedure

7.3 ELECTRICAL TESTS 7.3.1 Stator winding test 7.3.2 Rotor winding test 7.3.3 Excitation armature winding test 7.3.4 Excitation field winding test 7.3.5 Rotating diode bridge test 7.3.6 Electric panel test

7.4 CLEANING THE WINDINGS 7.4.0 General points 7.4.1 Coil-cleaning product

a) general b) Cleaning products

7.4.2 Cleaning the stator, rotor, excitation and diodes a) using specific chemical product b) Rinsing using soft water

7.5 DRYING THE WINDING 7.5.0 General points 7.5.1 Drying method

a) General points b) Drying generator stop c) Drying generator in rotation

7.6 RE-VARNISHING

10. FOLDOUT


ALTERNATORS

7

1. GENERAL INFORMATION

1.1 INTRODUCTION

1.1.0 General points This manual provides installation, operating and maintenance instructions for synchronous machines. It also describes the basic construction of these machines. This manual is general ; it applies to an entire group of synchronous generators. Additionally, in order to make information-finding easier, Section 1, "Characteristics and Performance", has been included, describing the machine completely (type of construction, type of bearing, protection index, and so forth...); this will enable you to determine exactly the chapters which apply to your machine. This synchronous machine has been designed for a maximum length of service. To achieve this, it is necessary to pay special attention to the chapter concerning the periodic maintenance schedule for the machines.

1.1.1 Safety notes The warnings "DANGER, CAUTION, NOTE" are used to draw the users attention to different points:

DANGER : THIS WARNING IS USED WHEN AN OPERATION, PROCEDURE, OR USE MAY CAUSE PERSONAL INJURY OR LOSS OF LIFE

CAUTION : THIS WARNING IS USED WHEN AN OPERATION, PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR DESTRUCTION OF EQUIPMENT

NOTE : This warning is used when an operation, procedure, or delicate installation requires clarification.

1.1.2 Conditions of use

a) Generalities A machine must only be installed, operated, by specifically trained persons. Any technical engineer who operate, maintain this machine must be allowed to practice in regard with local working laws (eg: to be certified to operate on high voltage devices ) A machine can only be operated for the duty foreseen by its original tender. The main data of this machine are summarized in "Section 1" of this manual Any operating condition other than those specified by the original tender must receive a Leroy Somer agreement Any modification of the machine structure must receive a Leroy Somer agreement

b) Vibratory analysis It is the responsibility of the gen set manufacturer to ensure that the different assembled system will be vibratory compatible.(ISO 8528-9) It is the responsibility of the gen set manufacturer to ensure that the shaft line torsional analysis has been done and accepted by the different parties (ISO 3046) CAUTION : EXCEEDING THE VIBRATORY LEVEL ALLOWED BY THE STANDARD ISO 8528-9 MAY CREATE HEAVY DAMAGES (BEARING DAMAGE, STRUCURE CRACKS ). EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF THE SHAFT LINE (ex: ABS, LLOYD ) MAY CREATE HEAVY DAMAGES (CRANKSHAFT FAILURE , GENERATOR SHAFT FAILURE, ) Refer to chapter 2.1.3 for further information about the accepted vibration level of the standard ISO 8528-9


ALTERNATORS

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1.2 GENERAL DESCRIPTION

1.2.1 Generator The synchronous generator is an alternating-current machine, without rings or brushes. The machine is cooled by the flow of air through the machine. For a batter comprehension, use the drawings of chapter 10.

1.2.2 Excitation system The excitation system is mounted on the side opposite the coupling. The excitation system comprises two assemblies: The excitation armature, generating a three-phase current, coupled with the three-phase rectifier bridge (comprised of six diodes) supplies the excitation current to the generator revolving field. The excitation armature and the rectifier bridge are mounted on the synchronous generator rotor shaft and are interconnected electrically with the revolving field of the machine. The excitation field winding (stator) is supplied by the control (in direct current)

5

43

1

2

1- Excitation field winding 2- Excitation armature 3- Rotating diode bridge 4- Revolving field 5- Machine stator


ALTERNATORS

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2. DESCRIPTION OF SUB-ASSEMBLIES

2.1 STATOR

2.1.1 Electric machine armature

a) Mechanical description The machine stator comprises low-loss steel laminations, assembled under pressure. The steel laminations are blocked axially by a welded ring. The stator coils are inserted and blocked in the slots, then impregnated with varnish, and polymerised to ensure maximum resistance to mould, excellent dielectric rigidity and perfect mechanical linking.

2.1.2 Excitation field winding The excitation field winding comprises a solid element and a winding. The excitation is flanged on the rear end shield of the machine. The winding is made of enamelled copper wires.

2.1.3 Stator protection

a) Heating resistor The heating element avoids internal condensation during the shutdown periods. It is connected to the main terminal box strip. The heating resistor is switched on as soon as the machine is shut down. It is located at the back end of the machine. The electrical characteristics are provided in Section 1 "Technical Characteristics".

b) Stator winding temperature sensor The temperature sensors are located in the active part of the stack. They are located in the zone assumed to be the hottest part of the machine. The sensors are connected to a terminal box. Depending on the temperature rise of the machine, the temperature of the sensors should not exceed a maximum of :

TEMP. RISE class

ALARM TRIP

Power (KVA) < 5000 > 5000 < 5000 > 5000 B 130 C 125 C 135 C 130 C

F 150 C 145 C 155 C 150 C

H 170 C 170 C 175 C 175 C

To improve the machine protection the alarm set point may be reduced following effective site information: Alarm temperature (*) = Highest recorded temp + 10K Trip temperature (*) = Alarm temperature + 5 K (*) do not pass over the values of the previous chart. (*)Highest recorded temp: Temperature measured at the site in the worst temperature condition at the stator temperature sensor E.g. : a class B machine reached 110C during a facto ry heat run test. Set the alarm temperature to 120C in stead of 130C as indicated in the previous chart. Set the emergency shutdown to 115C instead of 135C as indicated in the previous chart.

c) Stator air sensor As an option an RTD or thermostat can measure the stator air inlet temperature (cold air) Stator air inlet temperature; Alarm points and shutdown: alarm Nominal air inlet stator + 5 K shutdown 80C Stator air outlet temperature; Alarm points and shutdown: alarm Nominal air inlet stator + 35K shutdown Nominal air inlet stator + 40K NOTE : For an open drip proof machine the nominal air temperature entering the stator corresponds to the ambiant temperature Inhibit the stator air sensor safety "alarm" for few seconds during the machine start up; NOTE: For a water cooled machine (CACW) the nominal air entering the stator may be approximated as following: Tair entering stator = Twater entering cooler + 15K


ALTERNATORS

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d) Stator vibration sensor This chapter concerns the setting of seismic probes. For setting of proximity probes refer to the rotor chapter The vibration level of the machines is directly linked to the duty and to the site characteristics. We propose the following adjustment: Vibration Alarm (*) = Site Highest Vibration level + 50% Vibration Trip = Vibration Alarm + 50% (*) do not pass over the values of the following chart The machines are engineered to be able to withstand the vibration level indicated by the standard ISO8528-9 Engine speed ( RPM)

Power ( kVA )

Vibration level (mm/s ; RMS)

Engine Generator 1300 to 2199 > 250 < 45 < 20 721 to 1299 250 < 45 < 20 > 1250 < 45 < 18 720 > 1250 < 45 < 15 < 10 (*) (*) generator on concrete base

2.2 ROTOR

2.2.1 Revolving field-coil The revolving field coil comprises a stack of steel laminations, stamped and cut to reproduce the indentation of the projecting poles. The steel lamination stack-up is terminated at each end with high-conductivity electrical plates. To enable parallel operation between machines, and in order to ensure stability, high electrical conductivity bars are inserted in holes crossing the poles from one side to the other. These bars are welded with the stack end laminations in order to obtain a complete cage winding (or LEBLANC dampening cage). The winding (B) is placed around the pole (A) and is impregnated with epoxy resin (class F machine insulation) or with varnish (class H machine insulation). The winding is made of insulated flattened copper with high electrical conductivity. The aluminium plates (E) are pressed against the winding, acting as a heat dissipator and ensure excellent clamping of these coils. Support bars (C) on each pole protect the end windings against the centrifugal force. The revolving field-coil is heated and shrunk onto the shaft.

2.2.2 Excitation armature The excitation armature is constructed by stacking magnetic steel laminations. These steel laminations are held in place by rivets. The excitation coil is keyed and heat-shrunk onto the shaft. The windings are enamelled copper wires, class "F" insulation (or "H", depending on the customer's request or size of the machine).

2.2.3 Fan (machines: IC 0 A1) The synchronous machine is characterized by a self-ventilation system. A centrifugal fan is mounted between the revolving field coil and the front bearing. Air intake is at the rear of the machine and the exhaust on the drive end side. The fan consists of a hub, which is keyed and heat-shrunk onto the shaft. The flange is made of welded steel, attached to the hub with hexagonal head-cap screws. The ventilation effect is obtained through welded, inclined blades. The air exhaust is effected radially.

2.2.4 Rotating diode bridge a) General points The rectifier bridge, comprising six diodes, is placed at the rear of the machine. The rotating bridge is made of glass fibre with a printed circuit to connect the diodes together. This bridge is supplied with alternating current by the excitation armature and supplies direct current to the revolving field-coil. The diodes are protected against over voltage by rotating resistors, or by varistors. These resistors (or varistors) are mounted in parallel with the revolving field-coil.

+

-

1

2

3

1 - Field 2 - Rotating resistors 3 - Exciter armature


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The inner and outer rings are connected to the revolving field-coil

1

2

1 - Outer ring 2 - Inner ring The diode fastening screws must be tightened to the correct torque.

b) Tightening torque for the rotating diode fastening screws

CAUTION : THE ROTATING DIODE FASTENING SCREWS MUST BE TIGHTENED USING A TORQUE WRENCH CALIBRATED TO THE RECOMMENDED TORQUE.

Diode Tightening torque

SKR 100/.. 1.5 m.daN

SKR 130/.. 1.5 m.daN

SKN 240/.. 3 m.daN

c) Rotating rectifier test Carry out the test using a D.C. source as indicated below. A diode in good condition should allow the current to flow only in the anode-to-cathode direction. Disconnect the diodes before the test. 3 ... 48 volts

+-

1 2

1 - Anode 2 - Cathode

Diode type Positive Negative

SKR diode housing diode wire

SKN diode wire diode housing

When reassembling ensure that the diodes are be tightened to the correct torque

2.2.5 Balancing The entire rotor has been balanced according to ISO8221 standard in order to obtain a residual imbalance less than : Gen set : Class G2.5 Turbine : Class G1 The balancing is carried out at two levels. The first is that of the fan. It is recommended, when the fan is refitted (after servicing) to respect the initial indexing. The second is that of the shaft end. The shaft end is cold-stamped to indicate the type of balancing. H : balancing with Half-key carried out as standard F : balancing with Full key N : balancing without key (None) The coupling must be balanced to fit the generator rotor balancing.

2.2.6 Rotor vibration sensor This chapter concerns the setting of proximity probes. For setting of seismic probes refer to the stator chapter The vibration level of the machines is directly linked to the duty and to the site characteristics. We propose the following adjustment: Vibration Alarm (*) = 50% of the Bearing shell gap Vibration Trip = 75% of the Bearing shell gap


ALTERNATORS

12

2.3 ANTI FRICTION-BEARINGS

2.3.0 Description of antifriction bearings The bearings are installed at each end of the machine. They can be replaced. The bearings are protected from external dust by labyrinth seals. The bearings must be lubricated regularly. The old grease is forced out at the lower part of the bearings by the force of the new grease being injected.

2.3.1 Start-up of antifriction bearings The bearings are pre-lubricated in the factory, but before they are put into service, it is necessary to complete this lubrication.

CAUTION UPON START-UP, GREASE THE MACHINE WHILE IT IS RUNNING SO AS TO FILL ALL THE FREE SPACES IN THE GREASING DEVICE

Record the temperature of the bearings during the initial operating hours. Poor lubrication can cause abnormal heating. If the bearing hisses, lubricate it immediately. Some bearings may make a clattering noise if they do not operate at normal temperature. This may occur if the weather is very cold or when the machine is operating under abnormal temperature conditions (start-up phase, for example). The bearings will become quieter after having reached their normal operating temperature.

2.3.2 Storage of machine with anti friction bearings This chapter must be taken in consideration if a machine is stopped more than 6 months. Grease the bearings , machine stopped , inject two time the grease volume used for a standard maintenance. Every 6 months turn the the machine shaft line of few turns. Then inject a standard grease volume

2.3.3 Maintenance of antifriction bearings a) General points Antifriction bearings or ball bearings do not require special maintenance. They must be lubricated regularly with the same type of grease as used in the factory. For information concerning the lubrication quantity and interval, refer to Section 1 : "Characteristics and Performance".

CAUTION : LUBRICATION MUST BE CARRIED OUT AT LEAST EVERY 6 MONTHS

CAUTION : IT MUST BE DANGEROUS TO MIX GREASES WHICH HAVE DIFFERENT SOAP BASE. IT IS NECESSARY TO GET THE GREASE SUPPLIER APPROVAL OR TO CLEAN THE BEARING BEFOREHANDNOTE :

NOTE: After a regreasing the bearing temperature may increase of 10 to 20C This temporary temperature increase may stay few tens of hours

NOTE: For re greasing period lower than 2000 hours we recommend to install a continuous greasing system to limit the maintenance operators visit These type of system must be disable during machine stop The grease contained in these systems must not be stored over a period of 1 year

b) Lubricant Recommended lubricant: SKF LGWA2 or SHELL RETINAX LX2 (lithium complex base). Recommendation for a grease choice :: Mineral oil or PAO (SHC) Base (soap ) grade NLGI 2 Lithium complex base Base oil viscosity 100 to 200 mm2/s Dye penetration test (DIN 51817) : 2% minimum Use of grease which do not fit to the recomended figure (substitution grease) : Mineral oil or PAO (SHC) Base (soap ) grade NLGI 2 or NLGI 3 Lithium base Base oil viscosity 100 to 200 mm2/s Dye penetration test (DIN 51817) : 2% minimum CAUTION : THE USE OF A SUBSTITUTION GREASE CONDUCE TO REDUCE THE RE GREASING PERIOD OF 30%

NOTE: Lithium and complex lithium soap can be mixed


ALTERNATORS

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This note is applicable when the type of grease is changed. Dismantle the machine in order to get to the bearing Remove the old grease with a palette knife. Clean the lubricator and the grease removal tube. For greater cleaning efficiency, use a brush with solvent.

NOTE: The most widely-used solvent is gasoline : white spirit is acceptable.

DANGER: THE PROHIBITED SOLVENTS ARE: CHLORINATED SOLVENT (TRICHLORETHYLENE,TRICHLOROETHANE) WHICH BECOMES ACID FUEL-OIL (EVAPORATES TOO SLOWLY) GASOLINE CONTAINING LEAD BENZINE (TOXIC) Blow compressed air onto the bearings to evaporate the excess solvent. Fill the bearing with the new grease. Re-assemble the cage and the parts, which have been dismantled, filling them with grease. Use a grease pump to complete the bearing lubrication (while machine running)

2.3.4 Servicing the antifriction bearings

a) General points CAUTION: CLEANLINESS IS IMPERATIVE

b) Removing the bearings The inner bearing race is mounted, shrunk onto the shaft. The outer bearing race is free, or slightly tightened, on the hub (depending on the type of bearing). To remove the bearing from the shaft, it is necessary to use a hub-puller to avoid damaging the surface of the bearing.

c) Bearing re-assembly A bearing can be refitted if it is known to be in perfect condition Before refitting a bearing, carefully clean the surface of the bearing and the other parts of the bearing. To install the bearing on the shaft, it is necessary to heat the bearing. The heat source may be an oven or a space heater (the use of oil baths is strongly discouraged). CAUTION: NEVER HEAT A BEARING TO MORE THAN 125C (257F) Push the bearing up to the shaft shoulder, and check after cooling that the inner ring is still in contact with the shoulder. Lubricate using the recommended grease.

2.3.5 Antifriction bearing protection devices As an option, the bearing may be protected from over-heating by RTD or PTC sensors (customers choice).. For special use in warm surroundings where the temperature of the bearings exceeds the authorised limit (for a bearing known to be in good condition), contact us. Bearing; Alarm points and shutdown: alarm 90C (194F) shutdown 95C (203F)

To improve the machine protection the alarm set point may be reduced following site effective information: Alarm temperature (*) = Highest recorded temp + 15K (*) do not pass over the values of the previous chart. E.g. : At site the common bearing temperature is 60C . Set the alarm temperature to 75C instead of 90C as indicated in the previous chart


ALTERNATORS

14

2.3.9 Anti friction bearing installation drawing

Machine type A50

Drive end Non drive end 1 End shield 5 O-Ring 2 End cover 6 Non drive end shield 3 Ball bearing 6226 C3 7 End cover 4 End cover fixing screw 8 Ball bearing 6226 C3 9 Bearing pre load washer 10 End cover fixing screw


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2.3.9 Anti friction bearing installation drawing (following)

Machine type A52.2; Two bearings

Bearing assembly "Power plant" Drive end Non Drive end

1 End cover 5 End shield 2 End cover fixing screw 6 End cover fixing screw 3 Ball bearing 6232 MC3 7 End cover 4 End shield 8 Roller bearing NU 1028 MC3

Bearing assembly " Marine " Drive end Non Drive end

1 9 End shield 2 10 End cover 3 11 End cover fixing screw 4

same as "power plant"

12 Bearing pre load spring 13 Ball bearing 6226 C3 14 O-Ring


ALTERNATORS

16


Machines A53 and A54 :

Drive end side (2 bearing machine) Non drive end side 1 End shield 1 End shield 2 M12 stud 2 M12 stud 3 End cover 3 End cover 4 - Shaft 4 Shaft 5 Ball bearing 6232 MC3 5 Ball bearing 6328 MC3 6 Spring


ALTERNATORS

17


Machine type A56 ; Power plant (6 poles and more)

1 - End shield 4 - Fixed deflector 7 (4) screws chc M6/16 10 - Roller bearing NUP 244 2 - Outside bearing cover 5 - Rotating deflector 8 - Sensors 11 - Roller bearing NU 232 3 - (4) Stud bolt M12/150 6 - Nut 9 - Inside bearing cover 12 - snap ring

Machine type A56 ; Power plant (4 poles only)

1 - End shield 5 - Rotating deflector 9 - Roller bearing NUP 236 13 snap ring 2 - Outside bearing cover 6 - Nut 10 - Inside bearing cover 3 (4) Stud bolt M16-150 7 - Screw chc M6-16 11 - Roller bearing NU 232 4 - Fixed deflector 8 - Sensors 12 - 4 Stud bolt M12-126-36


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18

2.4 SLEEVE BEARINGS Note : For vertical machines refer to the attached specific bearing notice. Refer to the attached cut view in "chapter 10" for an easier understanding

2.4.0 Description of horizontal Sleeve bearings a) Physical description Rotation of the machine rotor is guided by Sleeve bearings. The bearing housing is constructed in two ribbed parts providing considerable heat extraction potential. The sleeve bearing comprises two half-shells with an external spherical shape. This allows self-alignment. The guiding surfaces of the sleeve bearing are covered with tin-based anti-friction metal. The spherical seat of the housing of the electrically insulated bearings is covered with an insulating coating. The positioning pin of the sleeve bearing in the housing is also insulated with an insulating bush. The lubrication ring, mounted free on the shaft, is made of brass. In order to simplify dismantling, the ring is cut in two parts, assembled using screws. A guide for the lubrication ring (synthetic materials) is attached to the upper bearing half-shell (for marine applications only). The floating labyrinth seals are cut in two parts, held together by an expandable ring. These seals are inserted in a support. A seal-positioning pin rests in the support to block it during rotation. The upper part of the housing is closed by means of a glass plug allowing observation of the rotation of the lubrication ring. A threaded metal plug allows the bearing to be filled with oil. The lower housing may be equipped with an oil-level sight indicator, a thermometer and a temperature sensor.

b) Operating description of Self-lubricating bearing Upon stopping, the shaft rests on the lower bearing; there is metal-to-metal contact. During the start-up phase, the shaft rubs against the anti-friction metal of the bearing. Oil lubrication is used. After having reached its transition speed, the shaft creates its oil film. At this point there is no further contact between the shaft and bearing.

CAUTION: PROLONGED OPERATION AT EXTREMELY SLOW ROTATION SPEEDS (SEVERAL rpm) WITHOUT LUBRICATION COULD SERIOUSLY DAMAGE THE SERVICE LIFE OF THE BEARING.

c) Operating description of Oil circulation bearing Proceed as for the self-lubricated bearings. For special duty of high speed machine or high loaded bearing it might be necessary to have an oil circulation system (external device which ensure the cooling and the circulation of the oil) The oil warmed by the bearing losses is externally cooled and is returned directly to the shell. To obtain efficient cooling the oil flow must be correct (refer to section 1).

2.4.1 Electrical insulation of Sleeve bearings a) Illustration diagram of the insulating film Following the used technology shaft circulating current may occurs. When necessary, ACEO insulates the Non Drive End bearing to avoid shaft-circulating current. An insulating film is applied to the bearing housing spherical seat.

1 Electrical insulation

CAUTION: WHEN INSULATED BEARING IS USED THE ACCESSORIES IN CONTACT WITH THE SHELL MUST BE ELECTRICALLY INSULATED (TEMPERATURE SENSOR )


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19

b) Insulation check Single bearing machine: Maintain the rotor at the drive end side to insulate it from the earth (disconnect the coupling if not done). Measure the insulating resistance between the shaft and the ground. The insulation should be better than 0.1 M. measured under 500 V DC

1

2

3

4

5

1 - Bearing shell 2- Insulating film 3 - Bearing housing 4 - Rotor 5 - Insulating wedging Double bearing machine: Maintain the rotor at the drive end side to insulate it from the earth (disconnects the coupling; Dismount the drive end bearing if not done). Measure the insulating resistance between the shaft and the ground. The insulation should be better than 0.1 M. measured under 500 V DC Installed shell accessories (e.g: RTD) must fit 0.1 M. measured under 500 V DC

2.4.2 Storage of Sleeve bearings machine a) General points CAUTION: WE RECOMMEND THE USE OF TECTYL PRODUCTS FROM VALVOLINE GmbH SUCH AS TYPE "511 M"

NOTE : It is possible to start the machine up without removing the "511.M" protection.

b) Short term storage When a sleeve bearing machine has to be stopped for more than one month and less than one year: Do not drain the bearing Pour the TECTYL protecting agent through the oil filling hole of the bearing (around 50 cc). Turn the shaft several times in order to spread the product evenly throughout the bearing.

c) Long term storage When a sleeve bearing machine has to be stopped for more than one year: Drain the bearing. Place a "Silicagel" gag inside the bearing oil sump (it is necessary to open the bearing housing to proceed) Place an adhesive strip along the parting lines of the housing. Pour the TECTYL protecting agent through the oil filling hole of the bearing (around 50 cc). Turn the shaft several times in order to spread the product evenly throughout the bearing.

CAUTION: A VISIT OF THE BEARING (research of corrosion marks) MUST BE DONE AT LEAST ONCE PER YEAR

CAUTION: BEFORE START UP IT WILL BE NECESSARY TO REMOVE THE "SILICAGEL" BAG AND TAPES

2.4.3 Oil circulation installation Refer to chapter 2.6

2.4.4 Start-up of Sleeve bearings a) General check before start up To identify your bearing characteristics refer to section 1 This verification must be carried out upon the first start-up, during periodic inspection of the bearing, or as soon as any part of the bearing alignment is changed (coupling ...). After a long shutdown period, proceed following the used storage procedure (refer to chapter 2.4.2) Check that the shaft has not corroded (onto journal surface; thrust faces and seals surfaces) Fill the bearing oil cavities with oil.

CAUTION: THE BEARINGS ARE DELIVERED WITHOUT OIL

Clean the external parts of the bearing. Dust and dirt impede the radiation of the heat Check if the temperature monitoring equipment works.


ALTERNATORS

20

b) Self-lubricating bearings start up data To identify your bearing characteristics refer to section 1 Fill the bearing with the recommended oil. The oil must be new, absolutely free of any traces of dust or water. The oil level limits are as follows: minimum oil level: bottom of the oil sight glass maximum oil level: 2/3 the top of the oil sight glass

NOTE: It is recommended to filter the oil before filling the bearing.

CAUTION: NOT ENOUGH LUBRICANT LEADS TO TEMPERATURE RISES AND THUS TO DAMAGE TO THE BEARING. TOO MUCH LUBRICANT LEADS TO LEAKAGES.

Retighten the split line and flange screws (12) by using the following torque values: Bearing Size 14 18 22 28

Torque [Nm] (lightly oiled)

170 330 570 1150

Check the firm position of the top sight glass (5). Check the firm position of the oil sight glass (23). If a temperature sensor or thermometer is used check they are correctly fixed. Retighten all screw plugs in the connection holes (4), (22), (24) (27) by using the necessary torque values: Plugs threads G 3/8 G 1/2 G 3/4 G 1

Torque [Nm] 30 40 60 110

Plugs threads G 1 1/4 G 1 1/2 G 2 G 2 1/2

Torque [Nm] 160 230 320 500 Check the operation of the temperature monitoring equipment. During the start-up period, check the temperature of the bearings. The temperature should stay below 95C an d then drop down to the temperature normally recommended (refer to the technical characteristics for Sleeve bearings in Section 1.) In case of oil oozing retighten the bearing fixing screws and the plugs to the recommended torque.

c) Water cooled bearing (type EFW..) start up data To identify your bearing characteristics refer to section 1 Proceed as for the self-lubricated bearings and check the water flow of the cooler. (refer to the data contained in section 1)

d) Oil circulation bearing with non accurate oil flow (+0% ; -40%)

To identify your bearing characteristics refer to section 1 This chapter typically applies for standard bearings (as for bearing types E..Z.K ; E..Z.Q). The oil circulating bearings (without Leroy Somer lubricating system) are delivered with: a breather an oil inlet flow regulating system. The "oil flow regulating system" consists of : an adjustable pressure reducing valve "A" a diaphragm. The oil flow adjustment does not request high accuracy. Do not feed the bearing with an oil flow higher than this one indicated in section 1. Ensure that the complete oil supply and return lines have been rinsed as instructed in the chapter.2.4.3 Ensure that the installation instructions have been followed (refer to chapter.2.4.3 ) such as filtering unit, return line properly inclined etc. Proceed as for the self-lubricated bearings and then start the oil supply system (pump etc.). To adjust the oil flow : Machine stopped, adjust the pressure reducing valve "A" to get the bearing oil level at the middle of the glass. And then run the generator Machine running and oil at the operating temperature the oil sight glass level should be within 1/3 and of the glass. If necessary readjust the pressure reducing valve "A"

A

During generator operation the oil level in the bearing must comply with the indications in Chapter 2.4.5.


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e) Oil circulation bearing with accurate oil flow (+5% ; -10%)

To identify your bearing characteristics refer to section 1 This chapter typically applies for bearings engineered for heavy thrust (tilting pads as for bearing types E..Z.A). CAUTION: THE OIL FLOW MUST BE CARREFULLY ADJUSTED TO THE REQUESTED VALUE

The oil circulating bearings are delivered with: a breather an oil inlet flow regulating system. The "oil inlet regulating system" consists of : an adjustable pressure reducing valve "A" a diaphragm. Ensure that the complete oil supply and return lines have been rinsed as instructed in the chapter.2.4.3 Ensure that the installation instructions have been followed (refer to chapter.2.4.3) such as filtering unit, return line properly inclined etc. Proceed as for the self-lubricated bearings and then start the oil supply system (pump etc.). The oil flow must be strictly adjusted within the requested value using a flow meter. Run the generator. Machine running and oil at the operating temperature the oil sight glass level should be within 1/3 and 2/3 of the glass. If the level reach the top of the oil sight glass investigate for the oil return line design.

f) Inspection of Sleeve bearings at the end of start-up Supervise the bearing during the trial run ( 5-10 operating hours ). Pay special attention to: - oil level - bearing temperature - sliding noises of the shaft seals - tightness - occurrence of vibrations.

CAUTION : IF THE BEARING TEMPERATURE EXCEEDS THE CALCULATED VALUE OF 15 k STOP THE MACHINE IMMEDIATELY. INSPECT THE BEARING AND DETERMINE THE CAUSES.

In case of oil oozing retighten the bearing fixing screws and plugs to the recommended torque

2.4.5 Maintenance of Sleeve bearings a) Verification of oil-level Check the oil level at regular intervals. The oil level limits are as follows: minimum oil level: bottom of the oil sight glass maximum oil level: 2/3 the top of the oil sight glass

Maximum admissible oil level

Optimum bottom oil levelOptimum top oil level

Minimum admissible oil level1/31/22/3

b) Temperature verification Check the bearing temperature and record it. A bearing temperature, which suddenly varies without any obvious reason (change of ambient temperature etc.), indicates abnormal operation. It is then necessary to inspect the bearing.

c) Oil draining NOTE: Risk of pollution! Please observe the instructions for the use of the lubricating oil. The manufacturer can provide information on waste oil disposal

It is recommended to drain the oil at intervals of 8000 hours of operation in dirty environment (eg : gen set application) 16000 hours of operation in clean environment (eg : hydro power plant) Shut down the installation and secure it against unintended operation. Take all necessary measures to collect all of the lubricating oil. Release the lubricating oil while it is still warm. Impurities and residues will thus be removed. Unscrew the oil drain plug (27). Release the lubricating oil and collect it.

NOTE: If the lubricating oil contains unusual residues or is visibly changed, eliminate the causes. If necessary, carry out an inspection.

Tighten the oil drain plug (27) using the following torque values:

Bearing size 14 18 22 28

Torque [Nm] 30 40 60 60 Remove the screw plugs from the oil filler hole (4).


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NOTE: Make sure that no impurities get into the bearing. Use a lubricant with the viscosity indicated on the bearing type plate. Fill the lubricant through the oil filler hole (4) up to the middle point of the oil sight glass (23). The oil level limits are as follows: minimum oil level: bottom of the oil sight glass maximum oil level: 2/3 the top of the oil sight glass

NOTE: Insufficient lubricant leads to temperature rises and thus to damage to the bearing. Too much lubricant leads to leakage. In the case of bearings lubricated by a loose oil ring, too much lubricant could break the oil ring, thus leading to damage to the bearing.

Tighten the screw plug into the oil filler hole (4) using the following torque values: Bearing size 14 18 22 28

Torque [Nm] 30 40 60 60

d) Pressure measurement of a Sleeve bearing housing The external environment of the electric machine may cause pressurizing or depressurizing of the Sleeve bearing and lead to oil leakage. Example: The oil return line (of a circulation bearing) opening directly into a diesel motor lower sump and allowing the housing back-pressure to return to the bearing. Example: A vacuum generated by a coupling located too close the Sleeve bearing and acting as a fan. The relative depression (or pressure) during operation must remain less than 5 mm of water column. The relative pressure is the pressure difference existing between the bearing oil sump and the bearing outside (measured close to the seals). Pe : external pressure close to the seal Pi : bearing oil sump pressure Pm : machine expansion chamber (gain access as indicated by the arrow) (Pe - Pi) < 50Pa (Pm - Pi) < 50Pa Note: 50Pa=5mmWC

Pe

Pm

Pi

Field pressure measure : Using a transparent tube as water column manometer. Connect a flexible transparent tube to the upper part of the bearing. Connect a pressure tap corresponding to the flexible tube used. Install the pressure tap in place of the filling plug located on the top of the bearing housing. Partially fill the pipe with water.

NOTE: Be careful not to cause water to enter the bearing

Measure the pressure (or depression) in millimeters of water column. NOTE: Given the low pressures measured, to make the reading easier it is advised to incline the water column manometer by 5.7 (diagram below). A reading amplification of "10" is thus obtained.

5 m

m

50 mm

5,7

5,7

100 mm10 mm

99mm

e) Oil for sleeve bearing We do not have any special recommendation regarding any mineral oil manufacturer. The used oil must comply with the requested viscosity (refer to Section 1). For frequent cold starting (lower than -15C) witho ut oil sump heater please contact us. A new oil viscosity may be advised. Use a non-foaming mineral oil, without additives. If an oil containing additives has to be used, make sure that the supplier confirms the chemical compatibility of the oil and the lead anti-friction properties.

CAUTION: SYNTHETIC OILS MAY BE USED ONLY IF USED LUBRICANT ARE ISSUED FROM THE FOLLOWING LIST

Since the synthetic lubricants are not standardized, no guarantee can be given regarding their chemical and mechanical behavior. Some synthetic lubricant may become acid and destroys bearing parts (white metal, oil ring, sight indicator..) in a short time If synthetic oil has to be used; during the first 2000 hours of use the lubricant should be checked at short intervals.


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Viscosity data (for information) :

246810121416182022

42403836343230282624

850775700625550500450400365315280240205175140115

8560402010

680

460

320

220

150

10068463222

140

90

85

75

80

0W & 5W10W20

30

40

50

A B C

yx

x - CST at 40C y - CST at 100C A - ISO (VG) B - SAE J306c Transmissions C - SAE J300d motors

Few examples of mineral oil:

viscosity ISO

viscosity (cSt ; 40C)

Type

ARAL VG 32 VG 46 VG 68

32 46 68

Vitam GF 32 Degol CL46 Degol CL 68

BP VG 32 VG 46 VG 68

31,5 46 68

Energol CS 32 Energol CS 46 Energol CS 68

CHEVRON VG 32 VG 46 VG 68

30,1 43,8 61,9

Mechanism LPS 32 Mechanism LPS 46 Mechanism LPS 68

ESSO VG 32 VG 46 VG 68

30 43 64

TERESSO 32 TERESSO 46 TERESSO 68

MOBIL VG 32 VG 46 VG 68

30 43 64

D.T.E. Oil Light D.T.E. Oil Medium D.T.E. Oil Heavy Medium

SHELL VG 32 VG 46 VG 68

32 46 68

Tellus Oil 32 Tellus Oil 46 Tellus Oil 68

The only synthetic lubricant allowed are those one issued from the following list

viscosit (cSt ; 40C)

Type

KLUBER 32 44 62 81

Summit SH 32 Summit SH 46 Summit SH 68 Summit SH 100

MOBIL 31 65

SHC 624 SHC 626

SHELL 32 48 68

Madrella Oil AS 32 Madrella Oil AS 46 Madrella Oil AS 68

f) Oil sump capacity (liters) Bearing EFxxx 14 18 22 28

Volume (l) 8 13 21 34


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g) Sealing Compound To ensure a good sealing effect and preserve a correct operation of the floating labyrinth seals of the bearings we recommend to use the following sealing compound: Mineral oil. On split surfaces and on the floating labyrinth seals it is possible to use following compounds (never dry): "Liquid gasket gray ; Three bond 1121" "Hylomar M ; Marton-Domsel" "Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh" On split surfaces only do not use on floating labyrinth seals) it is possible to use following compounds : Terostat-9140 ; Teroson Blue silicone RTV n6 ; Loctite Blue RTV 6B ; Permatex Hi-Temp RTV FAG 26B ; Permatex

Synthetic oils. Compound with a silicone base can pollute the synthetic oil. Use it only after checking with the oil manufacturer that it is compatible with the oil. Without compatibility information, use never dry silicone free compound, on all surfaces : "Liquid gasket gray ; Three bond 1121" "Hylomar M ; Marton-Domsel" "Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh"

2.4.6 Dismantling a) Tools and equipment The following tools and equipment are necessary: - Allan key set - Wrenching key set - Open-jaw spanner set - Feeler gauges (up 0.05mm) - Caliper gauge - Emery paper, Sleeve scraper - Lifting equipment - Permanent sealing compound (refer to chapter 2.4.5) - Clean cloth - Oil with the viscosity indicated (see bearing type plate) - Detergents - Liquid screw locking compound (e.g. LOCTITE 242) - Liquid sealing compound and Teflon tape.

DANGER BEFORE TRANSPORTING OR LIFTING CHECK IF THE EYE BOLTS ARE TIGHT! INSECURE EYE BOLTS COULD RESULT IN THE BEARING BECOMING LOOSE. BEFORE MOVING THE BEARING BY THE EYE BOLTS MAKE SURE THAT THE SPLIT LINE SCREWS ARE TIGHTENED, OTHERWISE THE BOTTOM HALF OF THE BEARING COULD BECOME DETACHED. MAKE SURE THAT THE EYE BOLTS ARE NOT EX POSED TO BENDING STRESS, OTHERWISE THE BOLTS COULD BREAK.

Follow exactly the instructions for the use of the lifting equipment.

NOTE: Make sure that the work place is clean. Contamination and damage to the bearing, especially of the running surfaces, have a negative influence on the operating quality and could lead to premature damage.

Shut down the installation and ensure that any unintended operation is prevented. Interrupt the cooling water supply (EFW.. bearing only). Remove all thermo sensors from the connection holes. Take all necessary measures to collect the lubricating oil. Unscrew the oil drain plug (27) and collect the lubricating oil (refer to chapter 2.4.5.c) b) Lifting equipment The following steps are to be observed before using the lifting equipment: To transport the complete bearing unit Check if the split line screws are tight (12): Check if the eye bolts are tight (6). Connect the lifting equipment to the eye bolts (6).


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To transport the top half of the housing Check if the eye bolts are tight (6). Connect the lifting equipment to the eye bolts (6). To transport the bottom half of the housing Screw 2 eye bolts (6) with suitable threads tight into the tap holes (17) marked with a cross. Bearing size 14 18 22 28

Tap hole M 16 M 20 M 24 M 30 Connect the lifting equipment to the eye bolts (6). To transport the Bearing shells Screw 2 eye bolts or screw hooks with suitable threads tight into the tap holes (9): Bearing size 14 18 22 28

Tap hole M 8 M 12 M 12 M 16 Connect the lifting equipment to the screw hooks.

c) Dismantling of the shaft seal type 10 (outboard side) Loosen all screws (55) and turn them off. Remove simultaneously in axial direction both top half (48) and bottom half (51) of the seal carrier from the housing. Shift the top half of the seal (53) a little (about 20 mm ). Tilt it over carefully until the hook spring (49) unbends. DANGER: DURING DISMANTLING OF THE FLOATING LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING (38). THIS IS UNDER TENSION AND COULD SPRING BACK AND LEAD TO INJURY.

Open the hook spring (49) and remove the bottom half of the seal (52) from the shaft. d) Dismantling of the shaft seal type 20 (outboard side) Untight all seals fixing screw (49) and remove them. Simultaneously remove in axial direction both top and bottom (48) ,(52) halves of the rigid labyrinth seal. - Remove the split line screws (50). - Separate the top half of the rigid labyrinth seal (59) from the bottom half (63). e) Dismantling of the top half of the housing Remove the flange screws (8). Remove the split line screws (12). Lift the top part of the housing (1) until the top part of the housing can be moved in axial line over the bearing shell, without touching it.

f) Removal of the top half of the shell Unscrew the split line screws (19) and lift the top half of the shell (11). CAUTION: DO NOT DAMAGE THE THRUST AND RADIAL RUNNING SURFACES.

g) Dismantling of the loose oil ring Open both split lines of the loose oil ring (44) by untightening and removing the screws (47). Separate both halves of the loose oil ring (44) carefully without using any tools or other devices.

Illustration 1 : Opening of the loose oil ring To check the geometry of the loose oil ring put it together as follows: Press the positioning pin (45) into the holes (46). Adjust both halves of the loose oil ring till the split lines match each other. Tighten the screws (47).


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h) Dismantling the machine side shaft seal Shift the top half of the seal (53) a little (about 20 mm). Tilt it over carefully until the hook spring (49) unbends. DANGER: DURING DISMANTLING OF THE FLOATING LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING (38). THIS IS UNDER TENSION AND COULD SPRING BACK AND LEAD TO INJURY.

Open the hook spring (49) and turn the bottom half of the seal (52) in the opposite direction to the anti-rotation pin out of the integrated seal groove of the bottom half of the housing.

i) Removal of the bottom half of the shell CAUTION: MAKE SURE THAT ALL BEARINGS MOUNTED ON A SHAFT LINE ARE OPENED. LOOSEN THE SPLIT LINE SCREWS OF THE HOUSINGS.

CAUTION: THE LIFTING EQUIPMENT SHOULD NOT COME IN TOUCH WITH THE SEAL AND RUNNING SURFACES OF THE SHAFT.

Lift the shaft up to the point where shaft and bottom half of the shell (13) do not touch each other any more. Protect the shaft against unintended movement. Turn the bottom half of the shell (13) out of the bottom half of the housing (21) and remove it from the shaft. j) Dismantling of the machine seal Usually it is not necessary to dismantle the machine seal (10) if maintenance works are carried out. If due to certain reasons the split machine seal must be dismantled please observe that this operation can be carried out only from the inner part of the machine. Loosen the split line screws of the machine seal and remove the flange screws (7). Non-split machine seals can be dismantled only after dismantling the machine shield or the shaft completely. In the case the machine seal is equipped with a hamp packing, some visible changes can be noticed, such as : tallow excess, black color of the seal due to temperature development. Even in such cases it is not necessary to renew the hamp packing. Color changes will appear with a new hamp packing too, until the seal clearance adjusts during operation.

2.4.7 Cleaning and checking a) Cleaning CAUTION: USE ONLY NON-AGGRESSIVE DETERGENTS SUCH AS FOR INSTANCE VALVOLINE 150 ALKALINE CLEANING COMPOUNDS (PH-VALUE 6 TO 9, SHORT REACTION TIME).

DANGER: PLEASE OBSERVE THE INSTRUCTIONS FOR THE USE OF THE DETERGENTS.

CAUTION: NEVER USE CLEANING WOOL OR CLOTH. RESIDUES OF SUCH MATERIALS LEFT IN THE BEARING COULD LEAD TO EXCESSIVE TEMPERATURES.

Clean the following parts thoroughly : top half of the housing (1) bottom half of the housing (21) top half of the shell (11) bottom half of the shell (13) sealing surfaces of the top half (48) and bottom half (51) of the seal carrier or of the rigid labyrinth seal loose oil ring (44).

Water cooler cleaning (bearing type EFW.. only) Check the condition of the oil cooler (26). In case the oil cooler (26) is encrusted with oil sludge: Dismantle the oil cooler. Remove the encrustation by using for instance a wire brush. Install the oil cooler (26) into the bearing.


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b) Wear checking Carry out a visual check of the wear condition of all bearing parts. The following graph provides information on the parts that must be replaced in case of wear. The right evaluation of the wear condition, especially of the running surfaces of the bearing shell, implies a lot of experience. If in doubt, replace the worn part with new ones. Part Wear condition Maintenance proceedings Shell Scoring

Bearing temperature before inspection: not increased no new shells increased new shells

White metal lining damaged

New shell

Bow wave ridges New shells Shaft seal

Baffles broken or damaged

New shaft seal

Loose oil ring

Geometrical form (roundness, flatness ) visibly changed

New loose oil ring

c) Insulation checking (only for insulated bearing) Check the insulating layer of the spherical seating (14) of the top half (1) and bottom half (21) of the housing. In case of damage contact Leroy Somer; dpartement ACEO factory.

2.4.8 Assembly of the Bearing CAUTION: REMOVE ALL IMPURITIES OR OTHER OBJECTS SUCH AS SCREWS, NUTS, ETC. FROM INSIDE THE BEARING. IF LEFT INSIDE THEY COULD LEAD TO DAMAGE OF THE BEARING. COVER UP THE OPENED BEARING DURING BREAKS.

CAUTION: CARRY OUT ALL ASSEMBLY OPERATIONS WITHOUT MAKING USE OF FORCE.

CAUTION: USE A LIQUID SCREW LOCKING COMPOUND (E.G. LOCTITE 242) FOR ALL HOUSING, SPLIT LINE AND FLANGE SCREWS.

a) Fitting in the bottom half of the shell Apply some lubricant on the spherical seating (14) in the bottom half of the housing (21) and on the running surfaces of the shaft. Use the same type of lubricant as indicated for bearing operation ( see type plate ). Place the bottom half of the shell (13) on the running surface of the shaft. Turn the bottom half of the shell (13) into the bottom half of the housing (21) with the split line surfaces of both halves in true alignment. In case the bottom half of the shell does not turn in easily, check the position of the shaft and the alignment of the bearing housing

CAUTION: (ONLY FOR BEARINGS EF..K) THESE OPERATIONS SHOULD BE CARRIED OUT MOST CAREFULLY. THE THRUST PARTS OF THE BOTTOM SHELL SHOULD NOT BE DAMAGED.

Lower down the shaft till it sits on the bottom half of the shell (13). b) Assembly of the shaft seal machine-side The machine-side shaft seal is standard-wise a floating labyrinth seal. The integrated seal groove is in the top and bottom halves of the housing.

DANGER: DURING ASSEMBLY HOLD THE HOOK SPRING ENDS (38) SECURELY TO AVOID THEM SUDDENLY RELEASING AND CAUSING POSSIBLE INJURY!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing: Put the hook spring (49) around the shaft and hook both ends into each other. Put both halves of the seal (52), (53) in their place on the shaft. Put the hook spring (49) into the spring groove (50). Turn the floating labyrinth seal on the shaft.


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CAUTION: THE FLOATING LABYRINTH SEAL SHOULD TURN EASILY ON THE SHAFT. A JAMMED SEAL COULD LEAD TO OVERHEATING DURING OPERATION AND EVEN TO SHAFT WEAR.

If the floating labyrinth seal jams, dismantle it from the shaft. Remove the worn parts of the seal carefully, by using emery paper or a Sleeve scraper. Dismantle the floating labyrinth seal. Apply sealing compound on the guide surfaces of the integrated seal groove in the bottom half of the housing.

Illustration 2: Coating of sealing compound on the integrated seal groove Apply a uniform layer of sealing compound on the seal surfaces and on the split line surfaces of both halves of the seal (52), (53).

Illustration 3 : Coating of sealing compound on the floating labyrinth seal Place the bottom half of the seal (52) with the labyrinths onto the shaft. The oil return holes at the bearing side must be opened. Turn the seal in the opposite direction to the anti-rotation pin into the groove of the housing until the split lines of the bottom half of the housing and the bottom half of the seal match each other. Remove the rest of the sealing compound. Push the spring hook into the integrated seal groove between the bottom half of the housing and the seal until both ends jut out from the split line. Place the top half of the seal with the cam facing the inside of the bearing on the bottom half of the seal. Stretch the hook spring until both ends can be hooked.

c) Installation of the loose oil ring Open both split lines of the loose oil ring (44) by untightening and removing the screws (47). Separate both halves of the loose oil ring (44) carefully without using any tools or other devices.

Illustration 4 : Opening of the loose oil ring Place both halves of the loose oil ring into the shell groove (13) encircling the shaft. Press the positioning pin (45) of each split line into the corresponding hole (46). Adjust both halves of the loose oil ring until the split lines match each other.

33

34

33

21

13

Illustration 5 : Installation of the loose oil ring Tighten the screws (47) by using the following torque values:


Torque [Nm] 1,4 2,7 2,7 2,7


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d) Fitting in the top half of the shell Apply some lubricant on the running surfaces of the shaft. Use the same type of lubricant as indicated for bearing operation (see type plate). Check if the engraved numbers (15) on the bottom and top halves of the shell correspond. Place the top half of the shell (11) on the shaft; both engraved numbers (15) should be on the same side. CAUTION : AN INCORRECTLY PLACED SHELL COULD JAM THE SHAFT THUS LEADING TO THE DAMAGE OF BOTH SHAFT AND BEARING.

CAUTION : (FOR BEARINGS TYPE EF..K ONLY) PLACE THE TOP HALF OF THE SHELL CAREFULLY ON THE SHAFT. THE THRUST PARTS OF THE TOP HALF OF THE SHELL SHOULD NOT BE DAMAGED.

Tighten up the split line screws (19) by using the following torque values: Bearing size 14 18 22 28

Torque [Nm] 20 69 69 170 Check the split line of the bearing shell by using a feeler gauge. The split line gap should be less than 0.05 mm. If the split line is greater than this, dismantle both top and bottom (11), (13) halves of the shell. Check the mobility of the loose oil ring (44). Marine bearing only: A guide bush in the top half of the shell secures the function of the loose oil ring. Check the mobility of the loose oil ring (44) in the guide bush.

e) Closing of the bearing Check the true alignment of the shell (11), (13) and bottom half (21) of the housing. The positioning pin (3) in the top half of the housing fits in the corresponding positioning pin hole (2). The bearing shell is thus placed into its right position. Check if the engraved numbers (20) on the top and bottom halves of the housing correspond. Clean the split line surfaces of the top and bottom halves (1), (21) of the housing. Apply sealing compound over the whole surface of the split line of the bottom half (21) of the housing. Place the top half of the housing carefully into the machine shield, without touching the seals or the bearing shell.

Lower the top half of the housing (1) vertically on the bottom half of the housing (21). Lower the top half of the housing (1) until the split line of the housing is not visible any more. Gently hit the bottom half of the housing (21) with a nylon hammer, thus ensuring the alignment of the spherical seating. Insert the split line screws (12). Tighten them hand-tight. Insert the flange screws (8). Tighten them using the following torque values: Bearing size 14 18 22 28

Torque [Nm] 170 330 570 1150 Tighten the split line screws (12) of the housing crosswise using the same torque values

f) Assembly of the type 10 Outboard Side Seals DANGER: DURING ASSEMBLY HOLD THE HOOK SPRING ENDS (49) SECURELY TO AVOID THEM SUDDENLY RELEASING AND CAUSING POSSIBLE INJURY!

Check the movement of the floating labyrinth seal on the shaft in the seal area outside the housing. Place the hook spring (49) around the shaft and hook both ends into each other. Locate both halves of the seal (52), (53) in their place on the shaft. Locate the hook spring (49) in the spring groove (50). Turn the floating labyrinth seal on the shaft.

CAUTION: THE FLOATING LABYRINTH SEAL SHOULD TURN EASILY ON THE SHAFT. A JAMMED SEAL COULD LEAD TO OVERHEATING DURING OPERATION AND EVEN TO SHAFT WEAR.

If the floating labyrinth seal jams, dismantle it from the shaft. Remove the worn parts of the seal carefully, by using emery paper or a Sleeve scraper. Dismantle the floating labyrinth seal. Apply a uniform layer of sealing compound on the seal surfaces and on the split line surfaces of both halves of the seal (52), (53).

Illustration 6 : Application of sealing compound on the floating labyrinth seal


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Press the bottom half of the seal (52) against the shaft. Place the top half of the seal (53) on the shaft and align both halves of the seal to each other. Place the hook spring (49) into the spring groove (50) and stretch until both ends can be hooked.

38 41 21

14243

Illustration 7 : Assembly of the floating labyrinth seal Align the split line of the floating labyrinth seal and the split line of the seal carrier. Check that both engraved numbers (56)and(58) on top and bottom halves of the seal carrier (48), (51) correspond. Clean the following: the seal surfaces of the top (48) and bottom (51) half of the seal parts: carrier (the groove of the floating labyrinth seal, the flange surfaces) the split line surfaces of the top (48) and bottom (51) half of the carrier the flange surfaces of the housing. Apply a uniform layer of sealing compound on: the lateral surfaces of the groove at the top (48) and bottom (51) half of the seal carrier the flange surfaces of the top (48) and bottom (51) half of the seal carrier the split line surfaces of the bottom half of the seal carrier (51).

Illustration 8 : Application of sealing compound on the seal carrier

Place the top half of the seal carrier (48) on the top half of the seal (53). Press the bottom half (51) of the seal carrier against it. Push the shaft seal completely into the housing.

Illustration 9 : Assembly of the seal carrier Align the split lines of the seal carrier and the housing. Tighten up the screws (55) by using the torque values: Bearing size 14 18 22 28

Torque [Nm] 8 20 20 20

g) Assembly of the type 20 Outboard Side Seals Check if the engraved numbers on the bottom half (63) and top half (59) of the rigid labyrinth seal correspond. Clean the flange surfaces of the top half and bottom half (63) of the rigid labyrinth seal the split line surfaces of the top half and bottom half (63) of the rigid labyrinth seal the flange surfaces of the housing. Apply a uniform layer of sealing compound on the following parts: the flange surfaces of the top (59) and bottom half (63) of the rigid labyrinth seal the split lines of the bottom half (63) of the rigid labyrinth seal.

Illustration 10: Application of sealing compound on the rigid labyrinth seal


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Place the top half (59) of the rigid labyrinth seal on the shaft and press slightly the bottom half (63) of the rigid labyrinth seal from below against it. Lightly push the rigid labyrinth seal completely into the housing. Tighten the split line screws (61). Place in parallel alignment the split line of the rigid labyrinth seal and the split line of the housing.

CAUTION: PRESS THE RIGID LABYRINTH SEAL FROM BELOW AGAINST THE SHAFT

Adjust the rigid labyrinth seal in such a way that the clearance "f" between the shaft and the rigid labyrinth seal at both split lines has the same figure.

Illustration 11: Alignment of the rigid labyrinth seal Tighten the screws (60) by using the following torque values:


Torque [N.m] 8 20 20 20

h) Assembly of the RD-thrust pads ; bearing type E...A Clean both top and bottom halves of the shroud ring and all RD-thrust pads.. Check if the parts show any visible damage. Carry out the assembly of both thrust parts of the top (6) and bottom (27) half of the shell according to the following instructions: An RD-thrust pad on both sides of the top half of the shell has a bore for the insertion of a thermo sensor ( thrust part temperature measurement). To mount the RD-thrust pad into the correct position proceed as follows: - Find the position of the location hole (38) on the top half of the shroud ring (39).Insert the RD-thrust pad (42) with the anti-rotation pin (43) into the corresponding thrust pad location hole (37). Insert all other RD-thrust pads (42) into the corresponding thrust pad holes (37) of the top and bottom half of the shell (6),(27).

Illustration 1: Assembly of the RD-thrust pads Place the top half of the shroud ring (39) into the top half of the shell (6) by inserting the anti-rotation pin (43) into the location hole (38). Match the split line of the top half of the shell (6) with the split line of the top half of the shroud ring (39) in true alignment.

Illustration 2: Assembly of the shroud ring Tighten the screws (40) by using the following torque values:


Tap hole M5 M6 M8 M10

Torque [N.m] 2,7 8 20 40 Place the bottom half of the shroud ring (41) into the bottom half of the shell (27). Match the corresponding split lines in true alignment. Tighten the screws (40) with the same torque value as valid for the top half of the shell (6). Check the mobility of all RD-thrust pads (42). If the RD-thrust pads jam, realign the top (39) and bottom half (41) of the shroud ring. CAUTION INSUFFICIENT MOBILITY OF THE RD-THRUST PADS WILL CAUSE DAMAGE OF THE BEARING.

Both top and bottom halves of the shells are prepared for assembly.


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2.4.9 Oil-leakage trouble-shooting Oil leakage can occur in the Sleeve bearings if certain measures are not taken.

a) Self-lubricating bearing - Is the oil level correct? (see chapter 2.4.5.a ) - Is the Sleeve bearing in decompression? (see chapter 2.4.5.d ). If the depression level is abnormal, add a protective screen. - Is the leakage occurring around the parting line? Clean the parting lines carefully with a solvent. Apply a sealing compound (refer to chapter 2.4.5) upon reassembly (see chapter 2.4.6) b) Oil circulation bearing - All information and instructions concerning the "self-lubricating bearings" apply. - Is the bearing oil flow correct (for data refer to section 1)? To adjust the oil flow refer to chapter 2.4.4 -Is the Sleeve bearing under pressure? To measure refer to chapter 2.4.5 . This pressure most certainly comes from the oil-return circuit. Check the oil-return circuit (refer to chapter 2.4.3 ). The back-pressure can often be eliminated by inserting a siphon-effect on the oil-return line (then make sure that the circuit modification does not disturb the oil-return flow).

2.4.10 Sleeve bearing protection devices a) Sight-level glass A sight-level gauge is placed on each bearing housing (on the left or the right). The level control method is described in chapter 2.4.5 a

b) Oil thermometer (optional) The thermometer gives the oil sump temperature. The recorded oil sump temperature must stay below 85C in normal condition.

c) Thermostat or sensor (optional) The recorded oil sump temperature must stay below 85C in normal condition. The shell temperature must stay below 90C in norma l condition. Shell metal ; Alarm points and shutdown: alarm 95C (203F) shutdown 100C (212F) Oil sump ; Alarm points and shutdown: alarm 85C (185F) shutdown 90C (194F) To improve the bearing protection the temperature set points can reduced following the effective site condition Alarm temperature (*) = Highest recorded temp + 5K Trip temperature (*) = Alarm temperature + 5 K (*)Highest recorded temp: Temperature measured at the site in the worst temperature Eg: A bearing reach 80C in the worst site condition Adjust the alarm set point to 85C instead of 95C a s previously recommended. Adjust the trip set point to 90C instead of 100C a s previously recommended.

d) Pre lub pump (optional) A pump takes up the oil from the bearing oil sump and pours it over the bearing shell. This pump ensures bearing lubrication, increasing the greasing effect during operation at very low speed and start up period Check the electrical connection of the pump motor to be sure of the rotation direction (the rotation direction is indicated on the pump). The pump has to be run few seconds before the synchronous machine starting (pre lub effect) and stopped as soon as the main shaft line pass over200 rpm For application having a long stop period (time over 5 minutes; eg: Steam Turbine, hydro turbine) the pump has to be run as soon as the speed pass below 200 rpm The pump has to be run continuously during barring period (eg: engine maintenance)


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2.6 OIL CIRCULATION LUBRICATING UNIT

2.6.0 General points Oil circulating bearing are noticeable by the third digit of their code. Letters "Z" ; "X" ; "U" indicate the use of an oil circulating bearing Example of oil circulating bearing : EFZLK ; ERXLA .. For engineering reason (need of cooling, need of lubrication) an external oil supply can be requested. Following the machine engineering the lubricating oil can come from different sources : Oil from the drive engine (System with gravity return) Oil lubricating unit (System with gravity return) Unit heater

2.6.1 Oil circulation by gravity return a) General This chapter applies for bearings, which need an oil circulation system The operating condition (sequences of operation, maintenance ) are given by a specific notice attached to the present one.

3

4 5

6

1

2

7

1 Oil inlet 2 Oil sight level indicator 3 Exhaust elbow 4 Immediate slope 5 Following ducts 6 Return oil sump 7 - Breather

Correct oil flow is obtained by regulating the pressure at the bearing inlet. (item 1)

b) Supply line To avoid excessive difficulties of cleaning, and to allow an easy ducting, it is necessary to use pipes requested for hydraulic duty After installation of the oil lines, rinse the entire oil circuit in order to avoid dirt or impurities entering inside the bearing and its connections. Rinse with washing oil. It is important to remove the instrumentation (for example, pressure gauge, flow-meter ...) during the rinsing operation to avoid any pollution.

NOTE: Never leave the Sleeve bearing on the rinsing circuit, as insoluble particles could enter the bearing and damage it.

The oil circulating bearings are equipped with an oil inlet pressure regulating system (item 1) The delivered oil pressure has to be reduced by the bearing system before entering the bearing (to adjust about 0.1 bar up to about 0.5 bar to get the correct oil flow, refer to chapter 2.4.4 for start up). A filtering unit must be installed on the supply system. The filtering power must be at least 25 (0.025 mm).

c) gravity oil return CAUTION: REMEMBER THAT THE OIL EXHAUSTED FROM THE BEARING GOES BACK TO THE TANK ONLY BY GRAVITY EFFECT

CAUTION: NOT TO FOLLOW THESE RULES MAY CAUSE HEAVY LEAKS BY BEARING SUMP OVERFLOW.

CAUTION: ADVISES AND REQUEST DONE IN THIS CHAPTER DO NOT ALLOW THE INSTALLATOR TO COMPLETE BY ITS OWN CALCULATIONS NEEDED FOR A CORRECT OPERATION OF ITS SYSTEM.

Some bearing may have two exhaust. In this case the both exhaust lies must be connected Because of the requested engineering rules the return ducts frequently have big size. Their manufacturing is frequently done by welding. It will be necessary to clean the welds and to rinse the oil lines before use.


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15

min

i : 30

0mm

"H

" >

20

0 m

m

60mini

Min Average slope: 150 mm / m

200 mmmini

Install a breather as close as possible of the bearing output The breather should be to a minimum of 200 mm above the highest point of the bearing. The breather line should be linked to the top side of the main oil line It is imperative to quickly go down after the bearing output: Install an elbow (minimum 60) immediately after th e bearing exhaust.(item 3) Pipe with a Minimum slope of 15 (so: a difference of 25 cm for 100cm long) minimum 300 mm high The difference of level between return oil sump and bearing exhaust must be strictly higher than "H"=200 mm The average slope of the return line must be strictly higher than 15 cm per meter of ground line. The average slope is based on the difference of level between bearing exhaust and return sump oil level. The oil return line must no be exposed to count

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